JP2017174896A - Solar cell module and manufacturing method of solar cell module - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a highly reliable solar cell module, by reducing impact on fixing strength when fitting a solar cell panel to a metal frame by using an elastic body.SOLUTION: A solar cell module 100 includes a first protective substrate 30, a first sealing layer 34, multiple solar cells 10, a second sealing layer 36, and a second protective substrate 32, to be laminated in order. The side face 30a of the first protective substrate 30 is coated with a protective member 35, and the second protective substrate 32 has a larger thickness in the lamination direction than the first protective substrate 30, and a larger outer periphery than the first protective substrate 30, and includes a laminate region C1 superposing the first protective substrate 30 in the lamination direction, and an outer peripheral region C2 on the outside of the laminate region C1.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a solar cell module and a method for manufacturing a solar cell module.

  The solar cell module has a plurality of solar cells. The plurality of solar cells are resin-sealed between the first protective member and the second protective member to form a solar battery panel. The solar cell panel is fixed by being fitted into a metal frame (see, for example, Patent Document 1).

International Publication No. 2012/128342

  The thickness of the solar cell panel may vary depending on manufacturing conditions and the like. When the solar cell panel is fixed by being fitted into a metal frame using an elastic body such as rubber packing, the fixing strength may be affected by variations in the thickness of the panel.

  The present invention has been made in view of such circumstances, and an object of the present invention is to reduce the influence on the fixing strength when the solar cell panel is fitted into the metal frame using an elastic body, and to improve the reliability of the solar cell. To provide a module.

  In order to solve the above problems, a solar cell module according to an aspect of the present invention includes a first protective substrate, a first sealing layer, a plurality of solar cells, and a second sealing layer, which are sequentially stacked. A second protective substrate. The side surface of the first protective substrate is covered with a protective member. The second protective substrate is thicker in the stacking direction than the first protective substrate, has a larger outer periphery than the first protective substrate, and overlaps the first protective substrate in the stacking direction and outside the stacked region. And the outer peripheral region.

  Another aspect of the present invention is a method for manufacturing a solar cell module. In this method, a first protective substrate, a first sealing material, a plurality of solar cells, a second sealing material, and a second protective substrate are disposed between the first jig and the second jig from the first jig. Arrange the laminated body sequentially in the direction toward the second jig, place an auxiliary jig on the outer periphery of the laminated body, and sandwich the laminated body between the first jig and the second jig and heat Crimping. The second protective substrate is thicker in the stacking direction than the first protective substrate, has a larger outer periphery than the first protective substrate, and overlaps the first protective substrate in the stacking direction and outside the stacked region. And the outer peripheral region. The auxiliary jig includes a first portion disposed between the first jig and the outer peripheral region of the second protective substrate, and the height of the first portion in the stacking direction is that of the first protective substrate and the solar battery cell. It is larger than the sum of the thicknesses and smaller than the sum of the thicknesses of the first protective substrate, the first sealing material, and the second sealing material.

  ADVANTAGE OF THE INVENTION According to this invention, the solar cell module which improved reliability can be provided.

It is sectional drawing which shows the structure of the solar cell module which concerns on embodiment. It is a top view which shows the structure of the solar cell panel which concerns on embodiment. It is a figure which shows typically the manufacturing process of a solar cell module. It is a figure which shows typically the manufacturing process of a solar cell module. It is a figure which shows typically the effect which the solar cell module which concerns on embodiment shows.

  Before describing the present invention in detail, an outline will be described. The embodiment of the present invention is a solar cell module. The solar battery module has a plurality of solar battery cells, and adjacent solar battery cells are connected by a connecting member called a tab wiring. Solar cells connected by tab wiring are resin-sealed between the first protective substrate and the second protective substrate to form a solar cell panel.

  The thickness of the solar cell panel may vary depending on manufacturing conditions and the like. For example, due to in-plane variations in the pressing force when laminating the laminate to form a panel, the position of the laminate on the hot plate, the positional relationship with other laminates arranged around, etc. The resin may be biased and the panel thickness may vary. Moreover, when using the template glass which has anti-glare property as a protective substrate, since the glass has wave | undulation in the manufacturing process of a template glass, or an air-cooling strengthening process, the convex part of glass plates used for both surfaces of a panel, or concave parts The locations where the two face each other are randomly generated, and the thickness of the panel may vary. If the thickness of the panel varies, the fixing strength of the panel to the frame may be affected when the solar cell panel is fitted into the metal frame using an elastic body such as rubber packing.

  Therefore, in the present embodiment, a second protective substrate having a larger area than the first protective substrate is adopted, and the second protective substrate is placed outside the stacked region where the first protective substrate and the second protective substrate overlap in the stacking direction. The outer peripheral area is provided. Further, the solar cell panel is fixed by making the second protective substrate thicker than the first protective substrate and fitting the outer peripheral region of the second protective substrate into the frame. Even if the thickness of the entire panel from the first protective substrate to the second protective substrate varies due to manufacturing conditions or the like, the first fixed to the frame is compared with the variation in the thickness of the entire panel. 2 The variation in the thickness of the protective substrate is relatively small. As a result, by fitting only the second protective substrate into the frame, it is possible to reduce the influence on the fixing strength due to the thickness variation as compared with the case where the entire panel is fitted into the frame. Further, by securing the fixing strength of the panel to the metal frame, it is possible to improve the reliability of the solar cell module particularly for a positive load.

  Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and repeated descriptions are omitted as appropriate.

  FIG. 1 is a cross-sectional view showing the structure of a solar cell module 100 according to an embodiment. FIG. 2 is a top view showing the structure of the solar cell panel 60. The solar cell module 100 includes a solar cell panel 60 and a frame 62. The solar panel 60 includes a plurality of solar cells 10, a tab wiring 20 that connects adjacent solar cells 10 to each other, a first protective substrate 30, a second protective substrate 32, and a first sealing layer 34. And a second sealing layer 36.

  The solar battery cell 10 is a layer that absorbs incident light and generates a photovoltaic force, and includes, for example, a substrate made of a semiconductor material such as crystalline silicon, gallium arsenide (GaAs), or indium phosphorus (InP). The structure of the solar battery cell 10 is not particularly limited. In this embodiment, the solar battery cell 10 has a heterojunction of an n-type single crystal silicon substrate and amorphous silicon. For example, the solar cell 10 includes an i-type amorphous silicon layer, a p-type amorphous silicon layer doped with boron (B) or the like on a light-receiving surface side of an n-type single crystal silicon substrate, indium oxide or the like. The transparent conductive layers made of a photoconductive oxide are stacked in this order. Further, an i-type amorphous silicon layer, an n-type amorphous silicon layer doped with phosphorus (P) or the like, and a transparent conductive layer are laminated on the back side of the substrate in this order.

  The photovoltaic cell 10 has a light receiving surface 12 that is one of the cell surfaces and a back surface 14 that is one of the cell surfaces and faces away from the light receiving surface 12. Here, the light receiving surface 12 means a main surface on which solar light is mainly incident in the solar battery cell 10, and is a surface on which most of the light incident on the solar battery cell 10 is incident. A light receiving surface electrode is formed on the light receiving surface 12, and a back electrode is formed on the back surface 14.

  The tab wiring 20 is an elongated metal foil. For example, a copper foil coated with silver, tin, solder, or the like, or an aluminum foil is used. The tab wiring 20 electrically and mechanically connects adjacent solar cells 10. One end of the tab wiring 20 is in electrical contact with the light receiving surface electrode formed on one light receiving surface 12 of the adjacent solar battery cell 10. The other end of the tab wiring 20 is brought into electrical contact with a back electrode formed on the other back surface 14 of the adjacent solar battery cell 10. The tab wiring 20 is bent in an inter-cell region between adjacent solar cells 10 so that the light receiving surface 12 and the back surface 14 of the adjacent solar cells 10 are arranged in the same plane. .

The first protective substrate 30 and the second protective substrate 32 are exterior members that protect the plurality of solar cells 10 from the external environment, and are, for example, glass substrates. The first protective substrate 30 is provided on the light receiving surface 12 side and transmits light in a wavelength band that the solar battery cell 10 absorbs for power generation. The second protective substrate 32 is provided on the back surface 14 side. The second protective substrate 32 is preferably thicker in the stacking direction than the first protective substrate 30 and has a thickness of 1.1 times or more that of the first protective substrate 30. By the thickness of the first protective substrate 30 t ₁ and providing a difference in thickness t ₂ of the second protective substrate 32, as the entire module when both of the thickness of the sum of (t 1 _{+ t 2)} to a constant The strength of can be increased. Since the strength of the glass is generally proportional to the square of the thickness, if the total thickness is constant, the sum of the strengths of the two glasses is minimum when both thicknesses are equal (t ₁ = t ₂ ). It is to become.

  A first protective member 35 is provided on the side surface 30 a of the first protective substrate 30. The first protection member 35 is provided along the outer periphery of the first protection substrate 30, and is provided along each of the four sides of the rectangular first protection substrate 30. The first protective member 35 has a role of protecting the first protective substrate 30 from an impact applied to the side surface 30 a of the first protective substrate 30. The first protective member 35 is preferably made of a resin material and is made of a thermosetting resin such as ethylene vinyl acetate copolymer (EVA) or polyimide. The first protective member 35 may be made of a polyethylene-based or polypropylene-based thermoplastic resin. The first protection member 35 may be made of the same material as at least one of the first sealing layer 34 and the second sealing layer 36 described later, and is integrated with the first sealing layer 34 and the second sealing layer 36. It may be formed automatically.

  The second protective substrate 32 has an outer periphery larger than that of the first protective substrate 30 and has a main surface having a larger area than that of the first protective substrate 30. As a result, the second protective substrate 32 includes a stacked region C1 that overlaps the first protective substrate 30 in the stacking direction, and an outer peripheral region C2 that is outside the stacked region C1. The outer peripheral area C <b> 2 is provided over the entire circumference of the second protective substrate 32, and the outer peripheral area C <b> 2 is provided along each of the four sides of the rectangular second protective substrate 32. In the modification, the outer peripheral area C <b> 2 may be provided only on three sides or two sides of the four sides of the second protective substrate 32. The outer peripheral area C2 of the second protective substrate 32 is fitted into the concave portion 64 of the frame 62 via a second protective member 66 such as a rubber frame.

In order to increase the fixing strength of the solar cell panel 60 with respect to the frame 62, the width (contact width) Wb in the in-plane direction where the second protective substrate 32 and the second protective member 66 are in contact is the thickness t ₂ of the second protective substrate 32. Larger is preferred. By increasing the contact width Wb between the second protective substrate 32 and the second protective member 66, the frictional force between the second protective substrate 32 and the second protective member 66 is increased, and the solar cell panel 60 is deformed to be bent. It can prevent coming off from the recessed part 64 of the frame 62. FIG. In order to ensure a sufficient contact width Wb for fixing the solar cell panel 60, the width Wa (width Wa in the direction in which the laminated region C1 and the outer peripheral region C2 are adjacent) provided with the outer peripheral region C2 is also the second protective substrate 32. it is preferable greater than the thickness t _2. This is because the width Wa of the outer peripheral region C2 is substantially the same as the contact width Wb between the second protective substrate 32 and the second protective member 66 or larger than the contact width Wb as shown in the figure. The width Wa of the outer peripheral region C2 is made larger than the thickness t ₂ of the second protective substrate 32, to ensure sufficient contact width Wb for fixing the solar cell panel 60, the fixing strength of the solar cell panel 60 with respect to the frame 62 Can be increased.

  The first sealing layer 34 and the second sealing layer 36 are sealing resin layers, and prevent moisture from entering the solar battery cell 10 and improve the strength of the entire solar battery module 100. The 1st sealing layer 34 is provided between the photovoltaic cell 10 and the 1st protective substrate 30, ie, the light-receiving surface 12 side. The second sealing layer 36 is provided between the solar battery cell 10 and the second protective substrate 32, that is, on the back surface 14 side. The first sealing layer 34 is a thermoplastic resin, for example, a polyethylene-based or polypropylene-based resin. The second sealing layer 36 is a thermosetting resin, for example, an ethylene-vinyl acetate copolymer (EVA), a polyethylene-based or polypropylene-based resin containing a polyimide or a cross-linking material. In addition, the material of the 1st sealing layer 34 and the 2nd sealing layer 36 is not restricted to these, In a modification, it is good also considering both the 1st sealing layer 34 and the 2nd sealing layer 36 as a thermoplastic resin. In addition, both the first sealing layer 34 and the second sealing layer 36 may be thermosetting resins.

  In the present embodiment, a resin having a lower melting point than that of the first sealing layer 34 is selected for the second sealing layer 36. That is, the resin material of the first sealing layer 34 has a relatively high melting point, and the resin material of the second sealing layer 36 has a relatively low melting point. The melting point of the resin material is, for example, at least when the average molecular weight of the polymer constituting the resin is large, when the ratio of the branched structure (weight to density) is high, and when the localized site is present in the main chain of the polymer In either case, the melting point increases. Therefore, by using resins having at least one of these different resin characteristics, the melting points of the first sealing layer 34 and the second sealing layer 36 can be made different. In addition, you may give the difference in melting | fusing point of a resin material using the characteristic different from the above-mentioned resin characteristic.

  The frame 62 is provided along the outer periphery of the solar cell panel 60 and is configured in a rectangular frame shape corresponding to the four sides of the rectangular second protective substrate 32. The frame 62 is formed of a metal material such as aluminum, iron, stainless steel, or a resin material. The frame 62 has a recess 64 for receiving the outer peripheral region C2 of the second protective substrate 32. The recess 64 is provided with a second protection member 66 made of an elastic body such as a rubber frame. The second protective member 66 has a role of filling the gap between the second protective substrate 32 and the concave portion 64 to increase the fixing strength and protecting the side surface 32 a of the second protective substrate 32.

  FIG. 3 is a diagram schematically showing a manufacturing process of the solar cell module 100. In this figure, the direction of the photovoltaic cell 10 is reversed upside down from FIG. A plurality of solar cells 10 are connected by tab wiring 20 to form a cell string 18. Next, the first sealing material 54 and the first protective substrate 30 are disposed on the light receiving surface 12 side of the cell string 18, and the second sealing material 56 and the second protective substrate 32 are disposed on the back surface 14 side. Subsequently, the first jig 40 and the first jig 40 are vertically moved so as to sandwich the laminate composed of the first protective substrate 30, the first sealing material 54, the cell string 18, the second sealing material 56, and the second protective substrate 32. The 2nd jig | tool 42 is arrange | positioned and it heats, applying a pressure to a laminated body. At this time, the first jig 40 is on the heating side, and the second jig 42 is on the pressing side. By thermocompression bonding, the first sealing material 54 and the second sealing material 56 are fused to form the first sealing layer 34 and the second sealing layer 36, and the solar cell panel 60 is completed. In the case where a thermosetting resin is used for at least one of the first sealing material 54 and the second sealing material 56, the thermosetting resin is obtained by putting the solar cell panel 60 into a resin curing furnace after thermocompression bonding. May be cured completely.

  In the above-described thermocompression bonding step, the first jig 40 is disposed so as to be in contact with the first protective substrate 30, and the second jig 42 is disposed so as to be in contact with the second protective substrate 32. The first jig 40 has a heating device 44 such as a heater. The heating device 44 heats the first protective substrate 30. The heat generated by the heating device 44 is transmitted in the order of the first protective substrate 30, the first sealing material 54, the cell string 18, the second sealing material 56, and the second protective substrate 32. In the present embodiment, the first sealing material 54 and the second sealing material 56 are heated by heating from the first protective substrate 30 having a small thickness, compared with the case of heating from the second protective substrate 32 having a large thickness. Heat can be transmitted easily. Further, by using a resin material having a low melting point for the second sealing material 56 that is harder to be heated than the first sealing material 54, the first sealing material 54 and the second sealing material 56 are almost at the same timing. It can be softened and fused. Thereby, the thermocompression bonding process can be completed in a shorter time, and an increase in manufacturing cost can be suppressed.

  In the above-described thermocompression bonding step, an auxiliary treatment is provided on the outer periphery of the laminated body 50 in which the first protective substrate 30, the first sealing material 54, the cell string 18, the second sealing material 56, and the second protective substrate 32 are sequentially laminated. A tool 70 is arranged. The auxiliary jig 70 positions the second protective substrate 32 having a larger area than the first protective substrate 30, and the first protective substrate 30, the first sealing material 54, and the cell string in the stacked region C <b> 1 of the second protective substrate 32. 18 and the second sealing material 56 are arranged. The auxiliary jig 70 includes a first portion 71 disposed in the outer peripheral region C <b> 2 of the second protective substrate 32 and a second portion 72 disposed outside the outer peripheral region C <b> 2 of the second protective substrate 32.

The first portion 71 is disposed adjacent to the first protective substrate 30 so as to surround the outer periphery of the first protective substrate 30. The first portions 71 are arranged to face each other with the first protective substrate 30 in between, and have a gap w ₃₁ wider than the width w ₁ of the first protective substrate 30. The interval w ₃₁ between the first portions 71 is smaller than the width w ₂ of the second protective substrate 32. As a result, the upper surface 71a of the first portion 71 can contact the outer peripheral region C2 of the second protective substrate 32 to support the second protective substrate 32. The width w ₃₂ of the upper surface 71a of the first portion 71 is preferably about the same as the width of the outer peripheral region C2 or wider than the width of the outer peripheral region C2. The height h ₁ of the first portion 71 is larger than the sum of the thicknesses of the first protective substrate 30 and the solar battery cell 10, and the first protective substrate 30, the first sealing material 54, and the second sealing material 56 have a height h ₁ . The thickness is preferably smaller than the sum of the thicknesses. Thereby, while supporting the 2nd protection substrate 32 so that the photovoltaic cell 10 may not be damaged at the time of thermocompression bonding, it can prevent that a clearance gap and a bubble are produced between the 1st protection substrate 30 and the 2nd protection substrate 32 after pressure bonding. .

The second portion 72 is disposed adjacent to the second protective substrate 32 so as to surround the outer periphery of the second protective substrate 32. The second portion 72 is disposed adjacent to the outside of the first portion 71 and is disposed so as to face the second protective substrate 32 with the interval w ₄ wider than the width w ₂ of the second protective substrate 32. . Thereby, the positional shift of the 1st protective substrate 30 and the 2nd protective substrate 32 in the surface direction can be suppressed. The height h ₂ of the second portion 72 is larger than the height h _{1 of} the first portion 71 and smaller than the sum of the thickness t ₂ of the second protective substrate 32 and the height h ₁ of the first portion 71. Is preferred. That is, it is desirable that the height h ₃ of the step between the upper surface 71 a of the first portion 71 and the upper surface 72 a of the second portion 72 is smaller than the thickness t ₂ of the second protective substrate 32. Thereby, a pressure can be reliably applied to the 2nd protective substrate 32 at the time of thermocompression bonding.

  In the illustrated example, the first portion 71 and the second portion 72 are integrated, but in a modified example, the first portion 71 and the second portion 72 may be separate. The auxiliary jig 70 may be disposed along each of the four sides of the rectangular first protective substrate 30 and the second protective substrate 32, or may be disposed along two or three sides of the four sides. Good. For example, the auxiliary jig 70 may be disposed along two opposing long sides of the first protective substrate 30 and the second protective substrate 32, but may not be disposed along the two opposing short sides. Good.

FIG. 4 is a diagram schematically showing the manufacturing process of the solar cell module 100, and shows the structure of the solar cell panel 60 that is heat-pressed. As illustrated, the first portion 71 of the auxiliary jig 70 is disposed between the first jig 40 and the second protective substrate 32 in the outer peripheral region C <b> 2 of the second protective substrate 32, and the second protective substrate 32. Support. Thereby, the same height h ₁ as the first portion 71 can be secured as the total thickness of the first protective substrate 30, the first sealing layer 34, and the second sealing layer 36. In addition, since the difference in height h ₃ between the first portion 71 and the second portion 72 is smaller than the thickness t ₂ of the second protective substrate 32, the laminated body between the first jig 40 and the second jig 42. The solar cell panel 60 can be formed by reliably heat-pressing 50.

  In addition, the first protective member 35 is formed on the side surface 30a of the first protective substrate 30 using the sealing material that protrudes outside the laminated region C1 during the thermocompression bonding. The first protective member 35 is formed using a gap between the first protective substrate 30 and the auxiliary jig 70. The first protective member 35 can be formed using, for example, a part of the first sealing material 54 that has been softened during thermocompression bonding. When a resin material that is difficult to soften is used as the material of the first sealing material 54, a part of the second sealing material 56 having a melting point lower than that of the first sealing material 54 is softened and the first protective member 35 is softened. May be formed. Moreover, when using a thermosetting resin for at least one of the 1st sealing material 54 and the 2nd sealing material 56, the 1st protection member 35 can also be formed with a thermosetting resin. By forming the first protective member 35 with a thermosetting resin, the strength of the first protective member 35 at a high temperature can be increased as compared with the case where a thermoplastic resin is used.

Next, the effect produced by the solar cell module 100 will be described.
FIG. 5 is a diagram schematically showing the effect exhibited by the solar cell module 100 according to the embodiment. The solar cell module 100 is installed such that the first protective substrate 30 is vertically upward and the second protective substrate 32 is vertically downward. The solar cell module 100 may be installed so that the first protective substrate 30 is orthogonal to the vertical direction, or may be installed obliquely so that the first protective substrate 30 intersects the vertical direction. When the solar cell module 100 is installed in a place with snowfall with the first protective substrate 30 vertically upward, snow is deposited on the first protective substrate 30 and the positive polarity as indicated by the arrow A from above the first protective substrate 30 is obtained. A load is applied.

  When a positive load is applied, bending occurs such that the center of the solar cell module 100 is directed downward. The first protective substrate 30 is subjected to compressive stress as indicated by arrow B, and the second protective substrate 32 is subjected to tensile stress as indicated by arrow C. In the solar cell module 100, since the first protective substrate 30 is thin and the second protective substrate 32 is thick, the neutral plane F of stress is close to the second protective substrate 32. Here, the neutral plane F refers to a place where no compressive stress or tensile stress is applied when the solar cell panel 60 is bent. The range closer to the first protective substrate 30 than the neutral plane F is the compression region D to which compressive stress is applied, and the range closer to the second protective substrate 32 than the neutral plane F is the tensile region E to which tensile stress is applied. is there. As shown in the drawing, the neutral plane F of the stress is located closer to the second protective substrate 32 than the solar battery cell 10, so that the solar battery cell 10 included in the compression region D is subjected to compressive stress. Become. The crystalline semiconductor material constituting the solar battery cell 10 has a characteristic that it is weak against tensile stress but strong against compressive stress. According to the present embodiment, by increasing the thickness of the second protective substrate 32, it is possible to prevent a tensile stress from being generated in the solar battery cell 10 even when a positive load is applied to the solar battery module 100. Thereby, damage of the photovoltaic cell 10 can be prevented and the reliability of the solar cell module 100 can be improved.

  According to the present embodiment, since the first protective substrate 30 with a small thickness is provided on the light receiving surface 12 side of the solar battery cell 10, the attenuation amount of incident light caused by the first protective substrate 30 can be reduced. This is because even if the glass substrate is transparent to the incident light, the transmittance of the incident light can be reduced as the glass substrate becomes thicker. Therefore, according to this Embodiment, more light can be entered into the photovoltaic cell 10, and the power generation efficiency of the photovoltaic module 100 can be improved.

  If the thickness of the first protective substrate 30 is reduced, the first protective substrate 30 may be easily warped depending on the external environment at the time of installation. For example, in summer when the intensity of sunlight is high, the solar battery cell 10 absorbs high-intensity incident light and becomes high temperature, and the temperature of the first protective substrate 30 also increases. Since the first protective substrate 30 has a small heat capacity, the first protective substrate 30 is likely to have a higher temperature than the second protective substrate 32. As a result, the amount of thermal expansion of the first protective substrate 30 is larger than that of the second protective substrate 32, and the solar cell panel 60 warps so that the outer surface (light receiving surface) of the first protective substrate 30 is convex. It will be. If it does so, tensile stress may be added to the photovoltaic cell 10 and it may lead to damage of the photovoltaic cell 10.

  On the other hand, in the present embodiment, a thermoplastic resin is used as the first sealing layer 34 between the first protective substrate 30 and the solar battery cell 10. Therefore, even when the first protective substrate 30 is warped due to the temperature rise of the solar cell module 100, the stress caused by the warp of the first protective substrate 30 due to the softening of the thermoplastic first sealing layer 34. Can be relaxed by the first sealing layer 34. Thereby, it is possible to prevent a strong tensile stress from being generated in the solar battery cell 10 and prevent the solar battery cell 10 from being damaged.

  According to the present embodiment, the first sealing layer 34 on the light receiving surface 12 side is made of a thermoplastic resin, while the second sealing layer 36 on the back surface 14 side is made of a thermosetting resin, so that the solar cell module. 100 reliability can be improved. If both the first sealing layer 34 and the second sealing layer 36 are made of a thermoplastic resin, the entire sealing layer softens when the solar cell panel 60 becomes high temperature and shifts to the arrangement of the cell strings 18. May occur, leading to damage to the solar battery cell 10. According to the present embodiment, at least one of the sealing layers is made of a thermosetting resin, thereby preventing displacement of the cell string 18 at a high temperature and damaging the solar battery cell 10 due to the displacement of the cell string 18. Can be prevented.

  According to the present embodiment, by forming the first protective member 35 on the side surface 30 a of the first protective substrate 30, damage to the first protective substrate 30 can be suppressed. In particular, the strength of the first protective member 35 can be further increased by using a thermosetting resin as the first protective member 35.

  According to the present embodiment, when the solar cell panel 60 is manufactured, the first protective substrate 30 having a small thickness is heated, thereby shortening the time required for the thermocompression bonding process and reducing the manufacturing cost of the solar cell panel 60. Can do. Further, by using the auxiliary jig 70 that supports the second protective substrate 32 having a size different from that of the first protective substrate 30, it is possible to prevent the second protective substrate 32 from warping in the thermocompression bonding step. In particular, it is possible to prevent warpage such that the outer peripheral region C2 of the second protective substrate 32 is deformed toward the first protective substrate 30, and to improve the uniformity of the thickness of the solar cell panel 60 after thermocompression bonding. By increasing the uniformity of the thickness of the solar cell panel 60, it is possible to facilitate attachment to the frame 62 and to prevent the positional deviation between the concave portion 64 of the frame 62 and the side surface 32a of the second protective substrate 32. Thereby, the fixing strength of the solar cell panel 60 with respect to the frame 62 can be ensured, and the reliability of the solar cell module 100 can be improved.

One aspect of this embodiment is a solar cell module (100). The solar cell module (100)
A first protective substrate (30), a first sealing layer (34), a plurality of solar cells (10), a second sealing layer (36), and a second protective substrate (32), which are sequentially stacked. And
The side surface (30a) of the first protective substrate (30) is covered with a protective member (35),
The second protective substrate (32) has a larger thickness in the stacking direction than the first protective substrate (30) and a larger outer periphery than the first protective substrate (30), and the first protective substrate (30 in the stacking direction). ) And the outer peripheral region (C2) outside the stacked region (C1).

  The protective member (35) may include the same material as at least one of the first sealing layer (34) and the second sealing layer (36).

In the second protective substrate (32), the width (w) of the outer peripheral region (C2) in the direction in which the laminated region (C1) and the outer peripheral region (C2) are adjacent is the thickness (t ₂ ) of the second protective substrate (32). May be larger.

The first protective substrate (30) is disposed on the light receiving surface side of the plurality of solar cells (10),
The second protective substrate (32) may be disposed on the back side of the plurality of solar cells (10).

  The second sealing layer (36) may have a lower melting point than the first sealing layer (34).

  The first sealing layer (34) may be a thermoplastic resin, and the second sealing layer (36) may be a thermosetting resin.

  The first protective substrate (30) may be installed on the upper side in the vertical direction.

Another aspect of the present embodiment is a method for manufacturing a solar cell module (100). This method
Between the first jig (40) and the second jig (42), a first protective substrate (30), a first sealing material (54), a plurality of solar cells (10), and a second sealing material (56) and arranging the laminate (50) in which the second protective substrate (32) is sequentially laminated in the direction from the first jig (40) to the second jig (42);
Placing an auxiliary jig (70) on the outer periphery of the laminate (50), sandwiching the laminate (50) between the first jig (40) and the second jig (42), and thermocompression bonding; With
The second protective substrate (32) has a larger thickness in the stacking direction than the first protective substrate (30) and a larger outer periphery than the first protective substrate (30), and the first protective substrate (30 in the stacking direction). ) And the stacked region (C1) and the outer peripheral region (C2) outside the stacked region (C1),
The auxiliary jig (70) includes a first part (71) disposed between the first jig (40) and the outer peripheral area (C2) of the second protective substrate (32), and the first part (71 ) is the stacking direction of the height of _{(h 1),} greater than the sum of the thickness of the first protective substrate (30) and the solar cell (10), the first protective substrate (30), the first sealing member ( 54) and the sum of the thicknesses of the second sealing material (56).

The auxiliary jig (70) further includes a second portion (72) disposed outside the second protective substrate (32), and the height (h ₂ ) of the second portion (72) in the stacking direction is It is larger than the height (h ₁ ) of the first portion (71) and smaller than the sum of the height (h ₁ ) of the first portion (71) and the thickness (t ₂ ) of the second protective substrate (32). May be.

  The thermocompression bonding means that at least one of the first sealing material (54) and the second sealing material (56) protrudes outside the laminated region (C1) and the side surface (30a) of the first protective substrate (30). May be coated.

  The first jig (40) may include a heating device (44), and the laminate (50) may be heated from the first protective substrate (30) side.

  As described above, the present invention has been described with reference to the above-described embodiment. However, the present invention is not limited to the above-described embodiment, and the present invention can be appropriately combined or replaced with the configuration of the embodiment. It is included in the present invention.

  C1 ... Laminated region, C2 ... Outer peripheral region, 10 ... Solar cell, 12 ... Light-receiving surface, 14 ... Back surface, 30 ... First protective substrate, 30a ... Side, 32 ... Second protective substrate, 34 ... First sealing layer , 36 ... second sealing layer, 40 ... first jig, 42 ... second jig, 44 ... heating device, 50 ... laminate, 54 ... first sealing material, 56 ... second sealing material, 60 DESCRIPTION OF SYMBOLS ... Solar cell panel, 70 ... Auxiliary jig, 71 ... 1st part, 72 ... 2nd part, 100 ... Solar cell module.

Claims (11)

A first protective substrate, a first sealing layer, a plurality of solar cells, a second sealing layer, and a second protective substrate, which are sequentially stacked;
A side surface of the first protective substrate is covered with a protective member,
The second protective substrate is thicker in the stacking direction than the first protective substrate, has a larger outer periphery than the first protective substrate, and a stacked region that overlaps the first protective substrate in the stacking direction; A solar cell module comprising an outer peripheral region outside the stacked region.   The solar cell module according to claim 1, wherein the protective member includes the same material as at least one of the first sealing layer and the second sealing layer.   3. The solar cell according to claim 1, wherein the second protective substrate has a width of the outer peripheral region in a direction in which the laminated region and the outer peripheral region are adjacent to each other, which is larger than a thickness of the second protective substrate. module. The first protective substrate is disposed on a light receiving surface side of the plurality of solar cells,
The solar cell module according to any one of claims 1 to 3, wherein the second protective substrate is disposed on a back surface side of the plurality of solar cells.   The solar cell module according to any one of claims 1 to 4, wherein the second sealing layer has a melting point lower than that of the first sealing layer.   The solar cell according to any one of claims 1 to 5, wherein the first sealing layer is a thermoplastic resin, and the second sealing layer is a thermosetting resin. module.   The solar cell module according to claim 1, wherein the first protective substrate is installed so as to be on an upper side in a vertical direction. Between the first jig and the second jig, the first protective substrate, the first sealing material, the plurality of solar cells, the second sealing material, and the second protective substrate are transferred from the first jig to the second jig. Arranging a laminated body sequentially laminated in a direction toward the jig;
Arranging an auxiliary jig on the outer periphery of the laminate, sandwiching the laminate between the first jig and the second jig, and thermocompression bonding,
The second protective substrate is thicker in the stacking direction than the first protective substrate, has a larger outer periphery than the first protective substrate, and a stacked region that overlaps the first protective substrate in the stacking direction; Including an outer peripheral region outside the laminated region,
The auxiliary jig includes a first part disposed between the first jig and the outer peripheral area of the second protective substrate, and the height of the first part in the stacking direction is the first part. A solar cell characterized in that it is larger than the sum of the thicknesses of the protective substrate and the solar cell and smaller than the sum of the thicknesses of the first protective substrate, the first sealing material and the second sealing material. Module manufacturing method.   The auxiliary jig further includes a second portion disposed outside the second protective substrate, and a height of the second portion in the stacking direction is greater than a height of the first portion, 9. The method for manufacturing a solar cell module according to claim 8, wherein the height of one portion is smaller than the sum of the thickness of the second protective substrate.   The thermocompression bonding includes covering at least one of the first sealing material and the second sealing material outside the laminated region so as to cover a side surface of the first protective substrate. The manufacturing method of the solar cell module of Claim 8 or 9.   11. The method for manufacturing a solar cell module according to claim 8, wherein the first jig includes a heating device, and the stacked body is heated from the first protective substrate side. .

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